Air gap spacer for use in building construction

ABSTRACT

An air gap spacer for use in building construction which can provide adequate spacing between the exterior surface of a building under construction, and the cladding or other exterior material being placed on the outer surface of the building, whereby the air gap spacer is disposed therebetween in order to provide an adequate air space which facilitates improved ventilation and water drainage through to the internal air gap, while allowing a firm backing to which exterior siding, shingles or brick may be attached. The air gap spacer is advantageously manufactured in 4′×8′ sheets of corrugated plastic, and, as such, will not rot. Application of the air gap spacer in 4′×8′ sheets involves less installation time, and, if necessary, a utility knife can be used to easily cut the air gap spacer sheet to size to fill in smaller areas.

CROSS REFERENCE TO RELATED APPLICATION

[0001] This application claims priority to Canadian Patent ApplicationNo. 2,414,055 filed on Dec. 12, 2002 and to Canadian Patent ApplicationNo. (not yet designated) filed on Nov. 18, 2003 both entitled Air GapSpacer for use in Building Construction, both having Clarence Thibeau asinventor.

[0002] 1. Background of the Invention

[0003] The present invention relates to an air gap spacer which isdesigned to be attached to an exterior surface of a building duringconstruction, and, more specifically, as an air gap spacer to be appliedbetween an exterior surface of a building and the cladding or otherexterior material being placed on the outer surface of the building, inorder to provide a sufficient air space and facilitate improved waterdrainage and ventilation while allowing a firm backing to which exteriorsiding, shingles or brick may be attached.

[0004] In the construction industry, National Building Code requirementsnormally stipulate that a minimum air gap be provided between theexterior sheathing of a building being constructed and the exteriorsiding or brick being placed thereon. As an example, the NationalBuilding Code of Canada requires that the minimum air gap be ⅜″ or 10mm. This is because climate changes could result in the external siding,shingles or brick expanding or contracting in response to variations intemperature, which may compromise the exterior surface of the building.Siding manufacturers also generally specify that a minimum air gap beprovided to ensure their product does not warp or buckle in everchanging conditions of temperature and humidity.

[0005] In the past, construction of an air space of this type wasusually achieved using wood (1″×3″ or milled strips) pieces which wouldbe attached to the wall at required spacing intervals. Utilizing such amethod would create an air gap when installed horizontally, but thislimits air circulation and water drainage. Further, the wooden stripscan eventually rot, causing structural damage and risk of insectinfestation.

[0006] 2. Description of the Prior Art

[0007] There are numerous examples of prior art devices designed for usein the construction industry when it is necessary to achieve support anduniform spacing between adjacent lengths of materials, such as whenapplying siding or clapboard to the side of a house, or shingles to theroof of a house.

[0008] U.S. Pat. No. 4,936,021 describes an adjustable support/spacerdevice for facilitating desired spacing between two adjacent surfacemembers, such as siding and the exterior surface of a building underconstruction. The device described therein is self-clamping to thematerial, such as shingles or siding, being applied to the exteriorsurface of the building under construction. However, utilization of sucha device is time-consuming, because to achieve the desired spacingnecessitates continual manual adjustment of the device, and does notadequately provide for a spacer device which efficiently provides forimproved ventilation and drainage characteristics.

[0009] Other types of prior art devices describe installing sidingpanels onto a support structure. U.S. Pat. No. 3,236,932 describeselongated metal strips which are used for applying metallic sidingpanels to a building structure without the use of nails or otherfasteners penetrating the siding panels. Thus, no holes are formed intothe siding panels. Each of the elongated metal strips has a central boxportion with side flanges containing holes. The metal strips arefastened with nails or screws along the flanges to the support wall. Thestrips also have vertically spaced clips for engaging the upper andlower edges of the siding panels.

[0010] Another example of this type of prior art device is described inU.S. Pat. No. 4,047,349, which teaches a sheet material attaching devicefor securing siding panels to a building. The attaching device is alongitudinal strip constructed from bendable sheet metal or plastic withsupport tabs which are integrally stamped-out segments of the strip.Preformed slots in the siding panel are engaged with the bendablesupport tabs which are then bent to secure the siding panel to the sheetmaterial attaching device. However these types of devices do not providefor an air gap spacer meant to provide spacing between the exteriorsurface of a building under construction, and the materials being placedon the outer surface of the building, in order to provide an air spaceand facilitate water drainage to the internal air gap, while allowing afirm backing to which exterior siding, shingles or brick may beattached.

[0011] Accordingly, there is a need in the construction industry toprovide a durable air gap spacer which requires less installation timeto install and which facilitates improved air circulation and waterdrainage capabilities. The present invention satisfies this need andprovides these benefits.

SUMMARY OF THE INVENTION

[0012] An object of the present invention is to provide an air gapspacer having improved ventilation and drainage characteristics, as wellas increased durability, and which is easily installed.

[0013] Another object of the present invention is to provide an air gapspacer which can provide a firmer and more even backing over a widerarea than conventional construction methods, with respect to theexterior shingles, siding or brick being applied thereon, over theexterior of the building.

[0014] According to an aspect of the present invention, an air gapspacer comprises a sheet material of substantially uniform thicknesscomprising a framework of interconnecting spacer members advantageouslyconfigured in a lattice-like pattern and having apertures therebetween,the sheet material being adapted for placement between a buildingconstruction sheathing material and an exterior cladding layer so as toprovide an air gap therebetween, wherein the spacer members includeinternally formed passages or openings therein, so as to permit aircirculation and water drainage from between the sheathing material andthe exterior cladding layer.

[0015] In another aspect of the present invention an air gap spacercomprises a sheet material of substantially uniform thickness comprisinga framework of interconnecting spacer members, the sheet material beingadapted for placement between a building construction sheathing materialand an exterior cladding layer so as to provide an air gap therebetween,wherein the spacer members include ventilation and drainage means formedtherein, so as to permit air circulation and water drainage from betweenthe sheathing material and the exterior cladding layer.

[0016] The air gap spacer of the present invention is advantageouslyformed with ventilation and drainage apertures or internal passages oropenings therein so as to facilitate improved air circulation and waterdrainage. The ventilation and drainage apertures can, for example, be inthe form of a depression or groove which is formed on an underside ofthe air gap spacer, particularly at the intersection of a pair of spacermembers. If, for example, moisture or condensation water accumulatesbetween the construction sheathing material and the exterior claddinglayer, the apertures or internally formed passages or openings of theair gap spacer of the present invention permit the moisture or rainwater to run along the air gap spacer, and away from the constructionsheathing material, e.g. plywood or chipboard, and the exterior claddinglayer, which may be e.g. aluminum or vinyl siding, shingles, brick,stone or stucco. The apertures or internally formed passages or openingsthen allow for water to pool thereon and drain within and out from belowthe air gap barrier formed therebetween.

[0017] The internally formed passages of the air gap spacer willnormally comprise vertically oriented passages, but it is conceivablethat the internally formed passages can also be formed in a diagonalorientation, or that some passages may be formed in a horizontal, orsomewhat horizontal, orientation.

[0018] Preferably, the air gap spacer of the present invention ismanufactured as 4′×8′ sheets of a corrugated recyclable plasticmaterial, such as Coroplast™, and is preferably ⅜″ (10 mm) thick, thoughit is possible to have different thicknesses of, for instance, from 10mm-20 mm, and is designed to be attached to the cladding on an exteriorwall of a building during construction. As it is preferably made ofplastic, the product will not rot and saves on lumber. The manufacturingof the air gap spacer in 4′×8′ sheets also means less installation timeis required to install and provide such an air gap, as compared toconventional construction methods, and facilitates improved aircirculation and water drainage capabilities. The air gap spacer isnormally to be installed in a vertically oriented manner, but it isconceivable that it can also be applied in a somewhat horizontalorientation.

[0019] If needed, a utility knife can quickly cut the air spacer sheetto size to fill smaller areas, as required, and to allow for window anddoor openings, eliminating “boxing in” the opening.

[0020] Preferably, the design of the air gap spacer in 4′×8′ sheets isin the form of a diamond pattern, effectively creating a lattice-likestructure. Normally, utilizing such a diamond pattern configuration forthe air gap spacer normally results in each ‘diamond’ in the sheet ofplastic material having 4″×6″ dimensions. Since the minimum surface ofshingles exposed to the elements is 4″, this design provides a firmerand more even backing over a wider area than conventional constructionmethods, with respect to the exterior shingles, siding or brick beingapplied thereon, over the exterior of the building. However, it isconceivable that each ‘diamond’ in each diamond pattern within the sheetof plastic material may have 4″×8″ dimensions, though in such anembodiment, it may be preferable to have an additional bridging portionstretching from side to side across the center of each individualdiamond pattern, so as to provide additional stability and strength tothe air gap spacer. It is also conceivable that the interconnectedspacer elements can be manufactured in square, hexagonal and rectangularconfigurations, rather than strictly a diamond pattern. It is furtherconceivable that the air gap spacer of the present invention could becollapsible for storage purposes, wherein the framework ofinterconnecting spacer members comprising the air gap spacer can befolded upon itself.

[0021] The 4″×6″, or 4″×8″, dimensions for the diamond pattern result in4 “diamonds” with a total horizontal width of 16″, thereby facilitatingnailing or screwing to the underlying studs of a sheathed wall.Similarly, two 8″ wide “diamonds” also result in a 16″ width.

[0022] The air gap spacer can be secured to the exterior wall of thebuilding being constructed, and the siding, shingles or brick positionedon the exterior surface of the building by way of securing means such asnails, screws or the like. As the spacer is made of plastic material,the securing means can be driven straight through the spacer to securethe spacer to the adjacent material, or, in an embodiment of the presentinvention, the air gap spacer can be formed having a plurality ofmounting holes therein, so as to facilitate the securing means beingplaced therethrough.

[0023] Prior to siding, brick or shingle installation, a strip of insectscreen, eg: 12″ wide, is advantageously attached to the bottom of thesheathing, and then lapped over the bottom of the air gap spacer, so asto restrict bugs and insects from entering and nesting within the airbarrier located between the exterior wall of the building beingconstructed, and the siding, shingles or brick to be positioned later onthe exterior surface of the building. Alternatively, the bottom of theair gap spacer can be manufactured with a strip of screen attachedthereto.

[0024] As described above, the present invention provides for an easilyand rapidly installed air gap spacer that provides for improvedventilation and drainage characteristics, and that can provide a morefirm and even backing over a wider area than conventional constructiontechniques, with respect to the exterior shingles, siding or brick beingapplied thereon, over the exterior of the building.

[0025] According to another aspect of the present invention there isprovided an air gap spacer for providing spacing between an outer wallsurface of a building under construction and an exterior claddingmaterial, the air gap spacer comprising: an apertured planar surface forattachment to a surface of the exterior cladding material to maintainthe cladding material in spaced relationship to the outer wall surface;and a plurality of mutually spaced protrusions of substantially uniformheight depending from one side of the apertured surface, the apices ofat least some of the protrusions forming a protrusion plane, theprotrusion plane being capable of attachment to the outer wall surfaceof the building; whereby, when the spacer is in place, liquid and airmay pass through channels formed among the protrusions to facilitate aircirculation and liquid drainage.

[0026] The protrusions advantageously depend from the apertured planarsurface at least approximately perpendicularly and may be disposedequidistantly over the planar surface of grouped or in concentratedareas thereof. The protrusions may be all alike, terminating to form theprotrusion plane. The protrusion plane is preferably at leastsubstantially parallel to the apertured plane. The apertured surface maycomprise aperture surface areas and matter surface area of similarmagnitudes and the apertured surface may comprise greater aperturesurface areas than matter surface areas. The apertures of the aperturedsurface may be of a repeating pattern over parts of or at leastsubstantially the entire spacer. The protrusions may be of a repeatingpattern over parts of or at least substantially the entire surface ofthe spacer. The apertures may be of at least the following shapes:diamond, circular, square, rectangular, oval and quadrilateral. Theprotrusions may be of at least the following shapes: pyramidal, flattopped pyramidal, conical, flat topped conical, rectangular basedpyramid, cuboid and rectangular block. The spacer may be made by atleast one of: injection moulding, pouring moulding, extrusion orstamping.

[0027] According to another aspect of the present invention there isprovided an air gap spacer comprising: an apertured sheet material of atleast substantially uniform thickness, the sheet material being adaptedfor placement between an outer wall surface of a building underconstruction and an exterior cladding material so as to provide an airgap therebetween, wherein the spacer material includes passages therein,so as to permit air circulation and liquid drainage among the apertures.The sheet material may be of a lattice structure forming diamond shapedapertures, the passages running through the lattice structure. Thepassages may be disposed at intersections formed by the spacer material.The air gap spacer may be adapted to be secured to the surface of thebuilding being constructed by way of securing means selected from thegroup consisting of tacks, nails and screws. The air gap spacer maycomprise a plurality of mounting holes therein, whereby securing meansmay be placed therethrough for attaching the spacer to the surface ofthe building being constructed.

[0028] The exterior cladding material may be one of: siding, shingles,brick and clapboard or another suitable material. The spacer may be madeof a material selected from the group consisting of plastic, metal,aluminum, and pressed wood particle product or other suitable material.

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Embodiments of the present invention will be further describedwith reference to the accompanying drawings, in which:

[0030]FIG. 1 is a perspective view of an uncut 4′×8′ sheet of the airgap spacer provided in accordance with the present invention;

[0031]FIG. 2 is a side elevational view of an air gap spacer accordingto an embodiment of the present invention, which illustrates drainageholes formed on a surface of the air gap spacer;

[0032]FIG. 3 is a top elevational view of the air gap spacer illustratedin FIG. 2, which illustrates an air gap spacer system according toanother embodiment of the present invention, wherein the air gap spaceris provided with nail mounting holes, whereby the air gap spacer can beattached to an adjacent material; and

[0033]FIG. 4 is a side elevational view of an air gap spacer accordingto another embodiment of the present invention, wherein the air gapspacer provides for a plurality of drainage and ventilation openingswhich are formed therein.

[0034]FIGS. 5 a,b,c are depictions of the shape of one surface of theair gap spacer according to certain embodiments of the presentinvention.

[0035]FIGS. 6 a,b,c are depictions of the shape of the protrusions ofthe air gap spacer according to certain embodiments of the presentinvention.

[0036]FIG. 7 is a perspective view of an example of an embodimentaccording to the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0037] Illustrated in FIG. 1 is a large uncut 4′×8′ sheet of the air gapspacer 1 of the present invention. In this embodiment, the uncut sheetutilizes a diamond pattern configuration 2.

[0038]FIG. 2 illustrates one embodiment of the present invention,whereby the air gap spacer of the present invention is formed with anindentation 3 on an underside thereon, so as to facilitate waterdrainage away from the exterior wall of the building and the siding,shingles or brick positioned on the exterior surface of the building,and to facilitate improved air circulation. The air gap spacer is formedof a corrugated plastic material 4, and the diamond pattern of the uncutsheet results in open areas 5 being formed within the uncut sheet. Theopen areas 5 within the uncut sheet reduces the total weight of the airgap spacer 1, making the air gap spacer easier to secure to adjacentsurfaces, and permits improved water drainage and air circulation.

[0039] Referring to FIG. 3, this figure illustrates the embodiment ofthe present invention introduced in FIG. 2, wherein the air gap spaceris provided with nail mounting holes 7, whereby the air gap spacer canbe secured to the exterior of a building.

[0040] Referring to FIG. 4, there is illustrated another embodiment ofthe present invention, whereby the air gap spacer is formed of acorrugated plastic material having a first surface 9 which overlies, andis spaced in parallel relationship to, a second surface 11. Spacerelements 13 are positioned along the length of the air gap spacer, thesebeing positioned at spaced intervals between the first 9 and secondsurfaces 11, whereby the spacer elements 13 are perpendicularlypositioned in relation to the first 9 and second 11 surfaces. The spacerelements 13 create a plurality of openings 15 within the air gap spacerof the present invention, to provide for drainage and ventilation.

[0041]FIGS. 5a, b and c, 6 a, b and c and 7 illustrate certainembodiments of the present invention. The air gap spacers shown arepartial planes, as seen in FIGS. 5a, b and c. Protrusions extend fromthe planar surface, as seen in FIGS. 6a, b and c. In this way, theamount of material used can be reduced and adequate air and liquid flowis achieved. In operation, the profiled surface is affixed to a buildingwall by tacking, adhesive or the like leaving the apertured planarsurface for application of the siding, shingles, brick or the like.

[0042] In FIGS. 5a, b and c the material is indicated with referencenumeral 16 and the spaces in between by reference numeral 17. Althoughdiamond, circle and square shapes are illustrated, many shapes could beused. In FIGS. 6a, b and c, the protrusions (18) are indicated withreference numeral 18. Although tapered square, conical and elongatedtriangular shapes are illustrated, many other shapes could be used. InFIG. 7, a perspective view of the protrusions (18) is illustrated.Sample dimensions are as follows: thickness of spacer 12 mm (height ofthe protrusions 11 mm), width of the base of a protrusion 5 mm, width ofthe apex of a protrusion 2 mm, distance between two adjacent protrusionsat their base 5 mm. Dimensions should be determined to achieveacceptable physical properties. Manufacturing methods may includepouring, extrusion or injection molding and stamping.

[0043] The spacers may be of various sizes, for instance (in feet) 4×8,4×4, 4×2, 2×2. The flat surface holes may be of various sizes, forinstance (in inches) 6, 4, 2. The protrusions are preferably not lessthan 10 mm apart. The thickness of the spacer is preferably at least 10mm.

[0044] The foregoing are exemplary embodiments of the present inventionand a person skilled in the art would appreciate that modifications tothese embodiments may be made without departing from the scope andspirit of the invention.

I claim:
 1. An air gap spacer for providing spacing between an outerwall surface of a building under construction and an exterior claddingmaterial, the air gap spacer comprising: an apertured planar surface forattachment to a surface of the exterior cladding material to maintainsaid cladding material in spaced relationship to the outer wall surface;and a plurality of mutually spaced protrusions of substantially uniformheight depending from one side of said apertured surface, the apices ofat least some of said protrusions forming a protrusion plane, theprotrusion plane being capable of attachment to the outer wall surfaceof the building; whereby, when the spacer is in place, liquid and airmay pass through channels formed among the protrusions to facilitate aircirculation and liquid drainage.
 2. An air gap spacer according to claim1, wherein said protrusions depend from said apertured planar surface atleast approximately perpendicularly.
 3. An air gap spacer according toclaim 1, wherein said protrusions are of like dimensions, terminating toform said protrusion plane.
 4. An air gap spacer according to claim 1,wherein said protrusion plane is at least substantially parallel to saidapertured plane.
 5. An air gap spacer according to claim 1, wherein saidapertured surface comprises aperture surface areas and matter surfacearea of similar magnitudes.
 6. An air gap spacer according to claim 1,wherein said apertured surface comprises greater aperture surface areasthan matter surface areas.
 7. An air gap spacer according to claim 1,wherein the apertures of the apertured surface are of a repeatingpattern over at least substantially the entire spacer.
 8. An air gapspacer according to claim 1, wherein said protrusions are of a repeatingpattern over at least substantially the entire surface of the spacer. 9.An air gap spacer according to claim 1, wherein the apertures areselected from a shape of the group consisting of: diamond, circular,square, rectangular, oval and quadrilateral.
 10. An air gap spaceraccording to claim 1, wherein said protrusions are selected from a shapeof the group consisting of: pyramidal, flat topped pyramidal, conical,flat topped conical, rectangular based pyramid, cuboid and rectangularblock.
 11. An air gap spacer according to claim 1, wherein the spacer ismade by at least one of: injection moulding, pouring moulding, extrusionor stamping.
 12. An air gap spacer comprising: an apertured sheetmaterial of at least substantially uniform thickness, the sheet materialbeing adapted for placement between an outer wall surface of a buildingunder construction and an exterior cladding material so as to provide anair gap therebetween, wherein the spacer material includes passagestherein, so as to permit air circulation and liquid drainage among saidapertures.
 13. An air gap spacer according to claim 12, wherein saidsheet material is of a lattice structure forming diamond shapedapertures, said passages running through the lattice structure.
 14. Anair gap spacer according to claim 12, wherein said passages are disposedat intersections formed by said spacer material.
 15. An air gap spaceraccording to claim 1, wherein the air gap spacer is adapted to besecured to the surface of the building being constructed by way ofsecuring means selected from the group consisting of tacks, nails andscrews.
 16. An air gap spacer according to claim 1, wherein the air gapspacer comprises a plurality of mounting holes therein, whereby securingmeans may be placed therethrough for attaching the spacer to the surfaceof the building being constructed.
 17. An air gap spacer according toclaim 1, wherein the exterior cladding material is one of: siding,shingles, brick and clapboard.
 18. An air gap spacer according to claim1, wherein the spacer is made of a material selected from the groupconsisting of plastic, metal, aluminum, and pressed wood particleproduct.
 19. An air gap spacer according to claim 12, wherein the airgap spacer is adapted to be secured to the surface of the building beingconstructed by way of securing means selected from the group consistingof tacks, nails and screws.
 20. An air gap spacer according to claim 12,wherein the air gap spacer comprises a plurality of mounting holestherein, whereby securing means may be placed therethrough for attachingthe spacer to the surface of the building being constructed.
 21. An airgap spacer according to claim 12, wherein the exterior cladding materialis one of: siding, shingles, brick and clapboard.
 22. An air gap spaceraccording to claim 12, wherein the spacer is made of a material selectedfrom the group consisting of plastic, metal, aluminum, and pressed woodparticle product.